High-pressure annular water collector with axial swirl vanes for an air cycle environmental control system

ABSTRACT

An annular water removal system (AWRS) for an air cycle environmental control system (ECS) includes a line replaceable unit (LRU) configured to output air flow, and a water collector coupled to the LRU. The water collector includes an upper portion and a lower portion. The upper portion includes a coalescing unit having a collector inlet to receive the air flow and configured to coalesce moisture from the air flow output from the LRU. The lower portion includes a collection unit in fluid communication with the coalescing unit. The collection unit is configured to collect the moisture coalesced by the coalescing unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 63/058,127, filed Jul. 29, 2020, the contents of which are herebyincorporated by reference in its entirety.

BACKGROUND

Exemplary embodiments pertain to an aircraft environmental controlsystem, and more particular, to an air cycle environmental controlsystem.

Air cycle machines (ACMs) are used as part of an aircraft environmentcontrol system (ECS) for processing a pressurized air source, such asbleed air from a gas turbine engine of an aircraft. For example, ACMsused in conjunction with heat exchangers, water collectors and controlvalves are used to process engine bleed air to achieve a desiredpressure, temperature, and humidity, which enable the ECS to provideconditioned air to the aircraft cabin and cockpit.

ACMs operate by compressing bleed air in a compressor section (i.e., acompressor), which is discharged to a downstream heat exchanger andfurther routed to a turbine system. The turbine system extracts energyfrom the expanded air to drive the compressor. The air output from theturbine system is utilized as an air supply for a vehicle, such as thecabin of an aircraft. The bleed air input to the compressor typicallyincludes ambient moisture (e.g., water). Therefore, an ECS commonlyincludes a water collector that collects and removes condensed waterfrom the processed air.

BRIEF DESCRIPTION

According to a non-limiting embodiment, an annular water removal system(AWRS) for an air cycle environmental control system (ECS) comprises aline replaceable unit (LRU) configured to output air flow, and a watercollector coupled to the LRU. The water collector comprises an upperportion and a lower portion. The upper portion includes a coalescingunit having a collector inlet to receive the air flow and configured tocoalesce moisture from the air flow output from the LRU. The lowerportion includes a collection unit in fluid communication with thecoalescing unit. The collection unit is configured to collect themoisture coalesced by the coalescing unit

According to a non-limiting embodiment, a water collector is providedthat is configured to remove moisture from air flow output from a linereplaceable unit (LRU). The water collector comprises an upper portionand a lower portion. The upper portion includes a coalescing unit havinga collector inlet to receive the air flow. The coalescing unit isconfigured to coalesce moisture from the air flow output from the LRU.The lower portion includes a collection unit in fluid communication withthe coalescing unit. The collection unit is configured to collect themoisture coalesced by the coalescing unit.

According to still another non-limiting embodiment, a method is providedto remove moisture from an air cycle environmental control system (ECS).The method comprises outputting air flow from a line replaceable unit(LRU) to a collector inlet of a water collector and conveying the airflow from the collector inlet to a coalescing unit included in an upperportion of the water collector. The method further comprises deliveringthe air flow through the coalescing unit to a collector outlet andcoalescing moisture from the air flow as it flows through the coalescingunit. The method further comprises delivering the coalesced moisture toa collection unit included in a lower portion of the water collector soas to collect the coalesced moisture.

Additional features and advantages are realized through the techniquesof the present disclosure. Other embodiments and aspects of thedisclosure are described in detail herein and are considered a part ofthe claimed technical concept. For a better understanding of thedisclosure with the advantages and the features, refer to thedescription and to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 is a perspective view of an annular water removal system (AWRS)including an annular water collector and line replaceable unit (LRU)according to a non-limiting embodiment;

FIG. 2 is a cross-sectional view of the AWRS shown FIG. 1 taken alongline A-A according to a non-limiting embodiment of the invention;

FIG. 3 is a perspective view of the annular water collector shown inFIG. 1 excluding the LRU according to a non-limiting embodiment;

FIG. 4 is a side-view schematic of the annular water collector shown inFIG. 3 according to a non-limiting embodiment;

FIG. 5 is a cross-sectional view of the annular water collector shown inFIG. 4 according to a non-limiting embodiment;

FIG. 6 is a cross-sectional view of an upper portion of the annularwater collector shown in FIG. 5 according to a non-limiting embodiment;

FIG. 7 is a cross-sectional view of a lower portion of the annular watercollector shown in FIG. 5 according to a non-limiting embodiment; and

FIG. 8 illustrates operation of an annular high-pressure water collectoraccording to a non-limiting embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

As mentioned above, an aircraft ECS commonly includes a high pressurewater collector (HPWC) that removes and collects the water fromprocessed ambient air. Conventional high pressure water collectorstypically include a primary flow passage extending along an elongatedhorizontal length to facilitate a centrifugation process for separatingmoisture from the air. The separated moisture is delivered to asecondary flow passage and into a settling chamber where pooled water isthen directed to other parts of the system for evaporative cooling ordischarged overboard. Conventional water collectors require three tofour duct diameters upstream of the large settling chamber to centrifugethe water droplets into a settling chamber and a method to induce about20 percent (˜20%) of the total flow into and out of the settlingchamber. An ejector is typically located at the outlet of the collectorto draw moisture laden secondary flow though the settling chamber.

Various non-limiting embodiments described herein provides an ECS thatincludes a high-pressure water collector configured to interact oroperate in conjunction with an LRU such as, for example, a condenser. Inat least one non-limiting embodiment, the water collector has an annularprofile and is configured to wrap around an annular condenser. Theannular water collector includes a plurality of axial swirl vanes influid communication with corresponding drain grooves. Airflow includingmoisture (e.g., water particles) impinges the axial swirl vanes suchthat the water is coalesced and centrifugally delivered to one or morewater grooves. The liquid water adheres to the grooves and flowscircumferentially due to the gravity down the side of the collector soas to deliver the liquid water to a plurality of holes located at thelower portion of each groove. The holes convey water into a collectorsump, due to a pressure gradient and gravity, where the water iscollected and subsequently ejected (e.g., sprayed) into an ECS heatexchanger for additional system evaporative cooling and/or can bedischarged overboard. The annular profile of the collector describedherein eliminates the need for multiple upstream duct diameters(length), separate pneumatic interface couplings, a separate settlingchamber and ejector associated with a conventional high pressure watercollector. Accordingly, the annular profile of the water collectorallows for reducing the overall packaging and size of the collector andoverall ECS.

With reference now to FIGS. 1-5, an annular water removal system (AWRS)100 capable of operating in an air cycle environmental control system(ECS) is illustrated in various views according to a non-limitingembodiment. The AWRS 100 includes a line replaceable unit (LRU) 102 anda high-pressure water collector 104. Although the LRU 102 and the watercollector 104 are described herein has having an annular or cylindricalprofiles, the specific dimensions are not limited thereto.

In a non-limiting embodiment, the LRU 102 includes an outer casing 101extending radially about a center axis (X-X). The LRU 102 can includevarious devices such as, for example, a condenser, a heat exchanger(HX), or a rotating machine. As mentioned above, the profile of the LRU102 includes, but is not limited to, an annular profile or a cylindricalprofile. The LRU 102 includes at least one exterior air inlet 106 and atleast one air outlet 108 (see FIG. 2). System air enters the at leastone air inlet 106 in a first direction (e.g., along the X-axis) that isparallel with the center axis (X-X). Accordingly, the LRU 102 isconfigured to process system air to generate high-pressure cooled airthat is expelled from the at least one air outlet 108.

The water collector 104 is coupled to the LRU 102 and is configured tocoalesce, collect and remove free moisture (e.g., water) from thecompressed air generated by the LRU. In one or more embodiments, thewater collector 104 is additively manufactured. Various known additivemanufacturing (AM) techniques can be performed to form the watercollector 104 using various known AM materials. The AM materials includemetallic materials such as, for example, aluminum, copper, etc., and/ornon-metallic materials such as polymers.

The water collector 104 can have a housing 103 extending radially aboutthe center axis (X-X) to define an annular profile with an opening 110that defines a diameter that is larger than the LRU diameter (See FIG.3). Accordingly, the LRU 102 can be disposed in the opening 110 suchthat the water collector 104 wraps entirely around at least a portion ofthe LRU 102 as shown in FIGS. 1 and 2. In some non-limiting embodiments,the LRU 102 is integrally fitted in the opening 110 via additivemanufacturing (see FIGS. 1 and 2) such that the water collector 104 andLRU form a monolithic structure. In other non-limiting embodiments, theLRU 102 is a separable component that is fitted in the opening 110. Incases where the LRU 102 is a separable component, an O-ring groove 135(sometimes referred to as a toric joint) is provided to fluidly seal theinterface between the LRU 102 and the water collector 104. In eithercase, the assembly and annular configurations of the LRU 102 and watercollector 104 enable distributed flow to be ported directly into or outof mating component plenums with minimal need for additional collectorplenums, external ducts, or couplings between annular heat exchanger 12and other components of environmental control system 10. Therefore,system assembly weight and volume can be reduced. Furthermore, pressurelosses (i.e., pressure drop) between mated components can be reduced.

In one or more embodiments, the water collector 104 includes an inletplenum 115 that extends around the entire circumference of the opening110 and is in fluid communication with the collector air inlet 114 (seeFIG. 5). Accordingly, the water collector 104 can be disposed in theopening 110 and fitted with the LRU 102 such that the air outlet 108 ofthe LRU 102 is in fluid communication with the inlet 115 (see FIG. 5) ofthe water collector 104. The air output from the LRU 102 can then becaptured in the inlet plenum 115 and delivered to the coalescing unit112 where moisture is coalesced as described in greater detail below.

Referring to FIGS. 5-7, the water collector 104 is illustrated ingreater detail. The water collector 104 includes an upper portion 105and a lower portion 107. The upper portion 105 includes a coalescingunit 112 having a collector inlet 114 and an outlet flange 116. Thecoalescing unit 112 configured to coalesce moisture from the airreceived from the air outlet 108 of the LRU 102. In one or morenon-limiting embodiments, the water collector 104 can coalesce andremove the moisture with a collection efficiency 95% or more.

The outlet flange 116 defines a collector outlet 118 configured to expelthe air (having a reduced amount of moisture) exiting the coalescingunit 112. In one or more non-limiting embodiments, the collector outlet118 has a torus profile and expels the air exiting the coalescing unit112 in a second direction (e.g., along the Y-axis) orthogonal to thefirst direction (e.g., the X-axis) and the center axis (X-X). Althoughthe collector outlet 118 is described as having a torus profile, thecollector outlet 118 is not limited thereto and can be additivelymanufactured to have various profiles capable of coupling to a secondLRU (not shown in FIGS. 5-7). The second LRU can include, for example, apre-heater unit configured to receive the air (having a reduced amountof moisture) output from the water collector 104.

Still referring FIGS. 5-7, the coalescing unit 112 includes a helicalair passage 120. The helical air passage 120 is defined by an inletchannel 122 that extends from the collector inlet 114, around atear-drop turn 124 (also referred to as a hairpin turn), and to anoutlet channel 126 that is in fluid communication with the collectoroutlet 118. The tear-drop turn 124 can be designed as a one-hundred andeighty degree (180°) tear-drop turn, for example. However, it should beappreciated that the specific degree of the tear-drop turn 124 may varyin degrees without departing from the scope of the invention. Thehelical air passage 120 promotes the coalescing of the water dropletsreceived from the upstream LRU 102 into rivulets. As the air flowtravels through the tear-drop turn 124, the cross sectional areaincreases and air flow begins to diffuse. As the air flow diffuses, itsflow velocity reduces, thereby improving the ability to separate themoisture from the air flow.

In one or more non-limiting embodiments, the inlet channel 122 includesan upper portion of one or more axial swirl vanes 128. The upper vaneportion extends between an inner surface of the inlet channel 122 andthe tear-drop turn 124. The axial swirl vanes 128 can be axiallyoriented either clockwise or counterclockwise and are configured topromote the collected moisture to flow in a common direction, therebyimproving the ability to collect the moisture (e.g., water droplets)from the slowed air flow.

The outlet channel 126 includes one or more collector grooves 130configured to collect moisture that adheres thereto after flowing fromthe inlet channel 122 into the outlet channel 126. Each collector groove130 is integrally formed in the inner surface of the housing 103 andincludes an upper groove portion that extends from the upper portion 105to a lower groove portion located at the lower portion 107. As thediffused air flow passes across the collector groove 130, free moistureadheres to the sidewalls of the grooves (e.g., via capillary action) andis directed to the lower portion 107 (e.g., via gravity) where it can becollected as described in greater detail below.

The outlet channel 126 may further include one or more optional supportvanes 132. The support vane 132 extends from a lower inner surface ofthe outlet channel 126 to an upper inner surface of the outlet channel126. The support vane 132 is oriented parallel with respect to the airflowing through the outlet channel 126 so as to minimize the pressuredrop within the water collector 104.

The lower portion 107 includes a collection unit 150 in fluidcommunication with the coalescing unit 112 and a drain port 152. Thecollection unit 150 is configured to collect the moisture coalesced bythe coalescing unit 112. In one or more non-limiting embodiments, thecollection unit 150 includes a lower portion of the axial swirl vanes128 and a sump 154. The lower portion of the axial swirl vanes 128extends to the upper portion of the axial swirl vanes via a vane body.The sump includes one or more drainage holes 156, which serve as fluidinlets. Each drainage hole 156 is in fluid communication with arespective collector groove 130 via a respective drainage hole 156.Accordingly, the moisture coalesced by the coalescing unit 112 andcollected by the collector grooves 130 can be delivered into the sump154.

The sump 154 further includes a sump outlet 158, which can eject (e.g.spray) the collected moisture (e.g., water) so as to remove the moisturefrom the water collector 104.

The water collector 104 can further including at least one gutter 134 influid communication with the inner surface of the housing 103. Thegutter 134 is configured collect moisture condensed on the outer surfaceof the housing 103 and deliver the collected moisture to the collectionunit 150. In one or more non-limiting embodiments, the gutter 134extends circumferentially to lower section 107 into adjacent groove 130and then into sump 154. Accordingly, moisture present on the outersurface of the housing can be delivered (e.g., primarily by gravity) tothe sump 150.

With reference now to FIG. 8, operation of an AWRS 100 including ahigh-pressure water collector 104 and LRU 102 is illustrated accordingto a non-limiting embodiment. In one or more non-limiting embodiments,the LRU 102 (shown in phantom) can be configured as a heat exchangerunit including an annular heat exchanger. The LRU 102 receives cooledoutput air 800 from a turbine (not shown), which is passed through acool flow path 802 of the annular heat exchanger. The secondary heatexchanger includes an air inlet 106, which receives compressed hot airflow 804. In one or more non-limiting embodiments, the hot air flow 804can be compressed ambient air output generated by a bleed source (notshown) and an ACM compressor (not shown). The compressed hot air flow804 is conveyed along a hot air flow path 806 from the air inlet 106 tothe collector air inlet 114, where it is enters the water collector 104.As the compressed hot air flow 804 travels from the air inlet 106 to thecollector air inlet 114, it flows counter to the cool output air 800 toperform a heat exchange process. The temperature difference between thehot air flow 804 and the cooled output air 800 causes moisture tocondense from the hot air flow 804.

As the compressed hot air flow 804 passes through the collector airinlet 114, it enters the helical air passage of the coalescing unit 112.Accordingly, the compressed hot air flow 804 passes around the axialswirl vanes 128 while flowing through the inlet channel 122. Thecompressed hot air flow 804 then turns and flows around the tear-dropturn 124 to enter the outlet channel 126. Accordingly, the compressedhot air flow 804 begins to diffuse and reduce in flow velocity. As thecompressed hot air flow 804 passes across the collector grooves 130,free moisture adheres thereto. The moisture is then directed to thelower portion of the water collector 104 (e.g., via gravity) where itcan be collected as described herein.

As described herein, one or more non-limiting embodiments provide an aircycle ECS including a high-pressure water collector configured tointeract or operate in conjunction with a condenser. In at least onenon-limiting embodiment, the water collector has an annular profile andis configured to wrap around the condenser. The annular water collectorincludes a plurality of axial swirl vanes and a plurality of collectorgrooves. Airflow including moisture (e.g., water particles) flows aroundthe axial swirl vanes such and passes across the collector grooves. Themoisture is coalesced from the air flow and adheres to the collectorgrooves. The collector grooves convey water into a collector sump due toa pressure gradient and gravity, where the water is collected. In one ormore embodiments, the collected water can be ejected (e.g., sprayed)from the collector sump and removed from the ACM.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof.

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

What is claimed is:
 1. A water collector configured to remove moisturefrom air flow output from a line replaceable unit (LRU), the watercollector comprising: an upper portion including a coalescing unithaving a collector inlet to receive the air flow, and configured tocoalesce moisture from the air flow output from the LRU; and a lowerportion including a collection unit in fluid communication with thecoalescing unit, the collection unit configured to collect the moisturecoalesced by the coalescing unit.
 2. The water collector of claim 1,wherein the water collector includes a housing extending radially abouta center axis to define an annular profile with an opening configured toreceive the LRU.
 3. The water collector of claim 2, wherein the watercollector is configured to wrap entirely around at least a portion ofthe LRU such that an air outlet of the LRU is in fluid communicationwith the collector inlet.
 4. The water collector of claim 2, wherein theupper portion further includes an outlet flange having a torus profilethat defines a collector outlet configured to expel the air exiting thecoalescing unit in a direction that is orthogonal to the center axis. 5.The water collector of claim 4, wherein the coalescing unit includes ahelical air passage.
 6. The water collector of claim 5, wherein thehelical passage is defined by an inlet channel extending from thecollector inlet, around a tear-drop turn, and to an outlet channel thatis in fluid communication with the collector outlet.
 7. The watercollector of claim 6, wherein the inlet channel includes at least oneaxial swirl vane extending between an inner surface of the inlet channeland the tear-drop turn.
 8. The water collector of claim 6, wherein theoutlet channel includes at least one collector groove configured tocollect moisture that adheres thereto responsive to conveying theairflow through the helical air passage.
 9. The water collector of claim8, wherein the at least one collector groove is integrally formed in theinner surface of the housing and extends from the upper portion to thelower portion so as to deliver moisture collected by the at least onecollector groove to the collection unit.
 10. The water collector ofclaim 9, wherein the outlet channel includes at least one support vaneoriented parallel with respect to the air flowing through the outletchannel so as to minimize the pressure drop within the water collector.11. The water collector of claim 9, wherein the collection unitincluding a sump configured to collect the moisture delivered by the atleast one collector groove.
 12. The water collector of claim 11, whereinthe sump includes a drain port to expel the moisture collected therein.13. The water collector of claim 9, wherein the coalescing unit furtherincludes at least one gutter in fluid communication with an outersurface of the housing so as to deliver moisture condensed on thehousing to the collection unit.
 14. The water collector of claim 6,further comprising at least one support vane extending from a lowerinner surface of the outlet channel to an upper inner surface of theoutlet channel, the at least one support vane oriented parallel withrespect to a direction of the air flow traveling through the outletchannel so as to reduce the pressure drop within the water collector.15. A method of removing moisture from an air cycle environmentalcontrol system (ECS), the method comprising: outputting air flow from aline replaceable unit (LRU) to a collector inlet of a water collectorand conveying the air flow from the collector inlet to a coalescing unitincluded in an upper portion of the water collector; delivering the airflow through the coalescing unit to a collector outlet and coalescingmoisture from the air flow as it flows through the coalescing unit; anddelivering the coalesced moisture to a collection unit included in alower portion of the water collector so as to collect the coalescedmoisture.
 16. The method of claim 15, wherein conveying the air flowfrom the collector inlet to a coalescing unit includes flowing theairflow through a housing of the water collector that extends radiallyabout a center axis to define an annular profile.
 17. The method ofclaim 16, wherein outputting air flow from the LRU to the collectorinlet further comprises wrapping the water collector entirely around atleast a portion of the LRU such that an air outlet of the LRU is influid communication with the collector inlet and outputting the airflowfrom the air outlet directly to the collector inlet.
 18. The method ofclaim 17, wherein delivering the air flow through the coalescing unitincludes conveying the air flow through a helical passage of thecoalescing unit defined by an inlet channel extending from the collectorinlet, around a tear-drop turn, and to an outlet channel that is influid communication with the collector outlet.
 19. The method of claim18, wherein coalescing moisture from the air flow as it flows throughthe coalescing unit further comprises passing the airflow across atleast one collector groove included in the coalescing unit andcollecting the moisture on the at least one collector groove as theairflow passes thereacross.
 20. The method of claim 19, whereindelivering the coalesced moisture to a collection unit comprises:conveying the moisture along the at least one collector groove to thecollection unit; and collecting the moisture conveyed from the at leastone collector groove in a sump located in the lower portion of the watercollector